Apparatus for radially expanding and plastically deforming a tubular member

An apparatus for radially expanding and plastically deforming a tubular member. In some embodiments, the apparatus includes a tubular support, sliding sleeve, rupture disc, and expansion cone. The tubular support has a first internal passage, wherein the sliding sleeve is disposed, and a flow passage, wherein the rupture disc is seated. The sliding sleeve has a second internal passage and is moveable by fluid pressure between first and second positions. In the first position, the second internal passage is fluidicly coupled with a first annulus surrounding the tubular support. In the second position, the second internal passage is fluidicly isolated from the first annulus. The rupture disc fluidicly isolates the first internal passage from a second annulus surrounding the tubular support and is adapted to rupture, whereby the first internal passage and the second annulus are fluidicly coupled. The expansion cone is disposed in the second annulus and moveable under pressure from fluid in the second annulus.

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Description
CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patent application Ser. No. 10/546,548, filed on Aug. 23, 2005, now U.S. Pat. No. 7,438,133, which is (1) a continuation-in-part of U.S. patent application Ser. No. 10/351,160, filed on Jan. 22, 2003, which issued as U.S. Pat. No. 6,976,541 on Dec. 20, 2005; and (2) the U.S. National Stage patent application for International patent application number PCT/US2004/006246, filed on Feb. 26, 2004, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/450,504, filed on Feb. 26, 2003, the entire disclosures of which are incorporate herein by reference.

BACKGROUND

The present disclosure relates generally to oil and gas exploration, and in particular to forming and repairing wellbore casings to facilitate oil and gas exploration.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1, 1a, 1b, 1c, and 1d are fragmentary cross-sectional illustrations of an exemplary embodiment of an apparatus for radially expanding and plastically deforming a tubular member during the placement of the apparatus within a wellbore.

FIGS. 2, 2a, 2b, 2c, and 2d are fragmentary cross-sectional illustrations of the apparatus of FIGS. 1, 1a, 1b, 1c, and 1d during the radial expansion and plastic deformation of the tubular member.

FIGS. 3, 3a, 3b, 3c, and 3d are fragmentary cross-sectional illustrations of the apparatus of FIGS. 1, 1a, 1b, 1c, and 1d during the injection of a hardenable fluidic sealing material into an annulus between the exterior of the apparatus and the wellbore.

FIGS. 4, 4a, 4b, 4c, and 4d are fragmentary cross-sectional illustrations of an exemplary embodiment of an apparatus for radially expanding and plastically deforming a tubular member during the placement of the apparatus within a wellbore.

FIGS. 5, 5a, 5b, 5c, and 5d are fragmentary cross-sectional illustrations of the apparatus of FIGS. 4, 4a, 4b, 4c, and 4d during the radial expansion and plastic deformation of the tubular member.

FIGS. 6, 6a, 6b, 6c, and 6d are fragmentary cross-sectional illustrations of the apparatus of FIGS. 4, 4a, 4b, 4c, and 4d during the injection of a hardenable fluidic sealing material into an annulus between the exterior of the apparatus and the wellbore.

FIGS. 7, 7a, 7b, 7c, 7d, and 7e are fragmentary cross-sectional illustrations of an exemplary embodiment of an apparatus for radially expanding and plastically deforming a tubular member during the placement of the apparatus within a wellbore.

FIGS. 8, 8a, 8b, 8c, and 8d are fragmentary cross-sectional illustrations of the apparatus of FIGS. 7, 7a, 7b, 7c, 7d, and 7e during the radial expansion and plastic deformation of the tubular member.

FIGS. 9, 9a, 9b, 9c, and 9d are fragmentary cross-sectional illustrations of the apparatus of FIGS. 7, 7a, 7b, 7c, 7d, and 7e during the injection of a hardenable fluidic sealing material into an annulus between the exterior of the apparatus and the wellbore.

FIG. 10 is a perspective illustration of an exemplary embodiment of an assembly including an exemplary embodiment of a tubular support, an exemplary embodiment of a one-way poppet valve, an exemplary embodiment of a sliding sleeve, and an exemplary embodiment of a tubular body.

FIG. 10a is a cross-sectional illustration of the assembly of FIG. 10 taken along line 10A-10A.

FIG. 10b is a cross-sectional illustration of the assembly of FIGS. 10 and 10a taken along line 10B-10B.

FIGS. 11, 11a, 11b, 11c and 11d are fragmentary cross-sectional illustrations of an exemplary embodiment of an apparatus for radially expanding and plastically deforming a tubular member during the placement of the apparatus within a wellbore, the apparatus including the assembly of FIGS. 10, 10a and 10b.

FIGS. 12, 12a, 12b, 12c and 12d are fragmentary cross-sectional illustrations of the apparatus of FIGS. 11, 11a, 11b, 11c and 11d during the injection of a fluidic material into an annulus between the exterior of the apparatus and the wellbore.

FIGS. 13, 13a, 13b, 13c and 13d are fragmentary cross-sectional illustrations of the apparatus of FIGS. 11, 11a, 11b, 11c and 11d during the radial expansion and plastic deformation of the tubular member.

FIGS. 14, 14a, 14b, 14c and 14d are fragmentary cross-sectional illustrations of an exemplary embodiment of an apparatus for radially expanding and plastically deforming a tubular member during the placement of the apparatus within a wellbore, the apparatus including an exemplary embodiment of a sliding sleeve.

FIGS. 15, 15a, 15b, 15c and 15d are fragmentary cross-sectional illustrations of the apparatus of FIGS. 14, 14a, 14b, 14c and 14d during the injection of a fluidic material into an annulus between the exterior of the apparatus and the wellbore.

FIGS. 16, 16a, 16b, 16c and 16d are fragmentary cross-sectional illustrations of the apparatus of FIGS. 14, 14a, 14b, 14c and 14d during the radial expansion and plastic deformation of the tubular member.

 DETAILED DESCRIPTION

Referring to FIGS. 1, 1a, 1b, 1c, and 1d, an exemplary embodiment of an apparatus 10 for radially expanding and plastically deforming a tubular member includes a tubular support 12 that defines an internal passage 12a and includes a threaded connection 12b at one end and a threaded connection 12c at another end. In an exemplary embodiment, during operation of the apparatus 10, a threaded end of a conventional tubular support member 14 that defines a passage 14a may be coupled to the threaded connection 12b of the tubular support member 12.

An end of a tubular support 16 that defines an internal passage 16a and radial passages, 16b and 16c, and includes an external annular recess 16d, an external flange 16e, and an internal flange 16f is coupled to the other end of the tubular support 12. A tubular expansion cone 18 that includes a tapered external expansion surface 18a is received within and is coupled to the external annular recess 16d of the tubular support 16 and an end of the tubular expansion cone abuts an end face of the external sleeve 16e of the tubular support.

A threaded connection 20a of an end of a tubular support 20 that defines an internal passage 20b and radial passages, 20c and 20d, and includes a threaded connection 20e, an external flange 20f, and internal splines 20g at another end is coupled to the threaded connection 12c of the other end of the tubular support 12. In an exemplary embodiment, the external flange 20f of the tubular support 20 abuts the internal flange 16f of the tubular support 16. Rupture discs, 22a and 22b, are received and mounted within the radial passages, 20c and 20d, respectively, of the tubular support 20.

A threaded connection 24a of an end of a tubular stinger 24 that defines an internal passage 24b and includes an external annular recess 24c and an external flange 24d at another end is coupled to the threaded connection 20e of the tubular support 20. An expandable tubular member 26 that defines an internal passage 26a for receiving the tubular supports 12, 14, 16, and 20 mates with and is supported by the external expansion surface 18a of the tubular expansion cone 18 that includes an upper portion 26b having a smaller inside diameter and a lower portion 26c having a larger inside diameter and a threaded connection 26d.

A threaded connection 28a of a shoe 28 that defines internal passages, 28b, 28c, 28d, 28e, and 28f, and includes another threaded connection 28g is coupled to the threaded connection 26d of the lower portion 26c of the expandable tubular member 26. A conventional one-way poppet valve 30 is movably coupled to the shoe 28 and includes a valve element 30a for controllably sealing an opening of the internal passage 28c of the shoe. In an exemplary embodiment, the one-way poppet valve 30 only permits fluidic materials to be exhausted from the apparatus 10.

A threaded connection 32a at an end of a tubular body 32 that defines an internal passage 32b, having a plug valve seat 32ba, upper flow ports, 32c and 32d, and lower flow ports, 32e and 32f, and includes an external flange 32g for sealingly engaging the interior surface of the expandable tubular member 26, external splines 32h for mating with and engaging the internal splines 20g of the tubular support 20, and an internal annular recess 32i is coupled to the threaded connection 28g of the shoe 28. Another end of the tubular body 32 is received within an annulus defined between the interior surface of the other end of the tubular support 20 and the exterior surface of the tubular stinger 24, and sealingly engages the interior surface of the tubular support 20.

A sliding sleeve valve 34 is movably received and supported within the internal passage 32b of the tubular body 32 that defines an internal passage 34a and radial passages, 34b and 34c, and includes collet fingers 34d at one end positioned within the annular recess 32i of the tubular body for releasably engaging the external flange 24d of the tubular stinger 24. The sliding sleeve valve 34 sealingly engages the internal surface of the internal passage 32b of the tubular body 32, and blocks the upper flow ports, 32c and 32d, of the tubular body. A valve guide pin 33 is coupled to the tubular body 32 for engaging the collet fingers 34d of the sliding sleeve valve 34 and thereby guiding and limiting the movement of the sliding sleeve valve.

During operation, as illustrated in FIGS. 1, 1a, 1b, 1c, and 1d, the apparatus 10 is positioned within a preexisting structure such as, for example, a wellbore 36 that traverses a subterranean formation 38. In an exemplary embodiment, during or after the positioning of the apparatus 10 within the wellbore 36, fluidic materials 40 may be circulated through and out of the apparatus into the wellbore 36 though the internal passages 14a, 12a, 20b, 24b, 34a, 32b, 28b, 28c, 28d, 28e, and 28f.

In an exemplary embodiment, as illustrated in FIGS. 2, 2a, 2b, 2c, and 2d, during operation of the apparatus 10, a conventional plug valve element 42 may then be injected into the apparatus through the passages 14a, 12a, 20b, 24b, 34a, and 32b until the plug valve element is seated in the plug seat 32ba of the internal passage of the tubular body 32. As a result, the flow of fluidic materials through the lower portion of the internal passage 32b of the tubular body 32 is blocked. Continued injection of fluidic materials 40 into the apparatus 10, following the seating of the plug valve element 42 in the plug seat 32ba of the internal passage of the tubular body 32, pressurizes the internal passage 20b of the tubular support and thereby causes the rupture discs, 22a and 22b, to be ruptured thereby opening the internal passages, 20c and 20d, of the tubular support 20. As a result, fluidic materials 40 are then conveyed through the internal passages, 20c and 20d, and radial passages, 16c and 16d, thereby pressurizing a region within the apparatus 10 below the tubular expansion cone 18. As a result, the tubular support 12, tubular support 14, tubular support 16, tubular expansion cone 18, tubular support 20, and tubular stinger 24 are displaced upwardly in the direction 44 relative to the expandable tubular member 26, shoe 28, tubular body 32, and sliding sleeve valve 34 thereby radially expanding and plastically deforming the expandable tubular member.

During the continued upward displacement of the tubular support 12, tubular support 14, tubular support 16, tubular expansion cone 18, tubular support 20, and tubular stinger 24 in the direction 44 relative to the expandable tubular member 26, shoe 28, tubular body 32, and sliding sleeve valve 34, the upward movement of the sliding sleeve valve is prevented by the operation of the valve guide pin 33. Consequently, at some point, the collet fingers 34d of the sliding sleeve valve 34 disengage from the external flange 24d of the tubular stinger 24.

In an exemplary embodiment, as illustrated in FIGS. 3, 3a, 3b, 3c, and 3d, during operation of the apparatus 10, before radially expanding and plastically deforming the expandable tubular member 26, the tubular support 12, tubular support 14, tubular support 16, tubular expansion cone 18, tubular support 20, and tubular stinger 24 are displaced downwardly in the direction 46 relative to the expandable tubular member 26, shoe 28, tubular body 32, and sliding sleeve valve 34 by, for example, setting the apparatus down onto the bottom of the wellbore 36. As a result, the other end of the tubular stinger 24 impacts and displaces the sliding sleeve valve 34 downwardly in the direction 48 thereby aligning the internal passages, 32c and 32d, of the tubular body 32, with the internal passages, 34b and 34c, of the sliding sleeve valve. A hardenable fluidic sealing material 50 may then be injected into the apparatus 10 through the internal passages 14a, 12a, 20b, 24b, and 34a, into and through the internal passages 32c and 32d and 34b and 34c, into and through an annulus 52 defined between the interior of the expandable tubular member 26 and the exterior of the tubular body 32, and then out of the apparatus through the internal passages 32e and 32f of the tubular body and the internal passages 28b, 28c, 28d, 28e, and 28f of the shoe 28 into the annulus between the exterior surface of the expandable tubular member and the interior surface of the wellbore 36. As a result, an annular body of a hardenable fluidic sealing material such as, for example, cement is formed within the annulus between the exterior surface of the expandable tubular member 26 and the interior surface of the wellbore 36. Before, during, or after the curing of the annular body of the hardenable fluidic sealing material, the apparatus may then be operated as described above with reference to FIG. 2 to radially expand and plastically deform the expandable tubular member 26.

Referring to FIGS. 4, 4a, 4b, 4c, and 4d, an exemplary embodiment of an apparatus 100 for radially expanding and plastically deforming a tubular member includes a tubular support 112 that defines a internal passage 112a and includes a threaded connection 112b at one end and a threaded connection 112c at another end. In an exemplary embodiment, during operation of the apparatus 100, a threaded end of a conventional tubular support member 114 that defines a passage 114a may be coupled to the threaded connection 112b of the tubular support member 112.

An end of a tubular support 116 that defines an internal passage 116a and radial passages, 116b and 116c, and includes an external annular recess 116d, an external flange 116e, and an internal flange 116f is coupled to the other end of the tubular support 112. A tubular expansion cone 118 that includes a tapered external expansion surface 118a is received within and is coupled to the external annular recess 116d of the tubular support 116 and an end of the tubular expansion cone abuts an end face of the external sleeve 116e of the tubular support.

A threaded connection 120a of an end of a tubular support 120 that defines an internal passage 120b and radial passages, 120c and 120d, and includes a threaded connection 120e, an external flange 120f, and internal splines 120g at another end is coupled to the threaded connection 112c of the other end of the tubular support 112. In an exemplary embodiment, the external flange 120f of the tubular support 120 abuts the internal flange 116f of the tubular support 116. Rupture discs, 122a and 122b, are received and mounted within the radial passages, 120c and 120d, respectively, of the tubular support 120.

A threaded connection 124a of an end of a tubular stinger 124 that defines an internal passage 124b and includes an external annular recess 124c and an external flange 124d at another end is coupled to the threaded connection 120e of the tubular support 120. An expandable tubular member 126 that defines an internal passage 126a for receiving the tubular supports 112, 114, 116, and 120 mates with and is supported by the external expansion surface 118a of the tubular expansion cone 118 that includes an upper portion 126b having a smaller inside diameter and a lower portion 126c having a larger inside diameter and a threaded connection 126d.

A threaded connection 128a of a shoe 128 that defines internal passages, 128b, 128c, 128d, 128e, and 128f, and includes another threaded connection 128g is coupled to the threaded connection 126d of the lower portion 126c of the expandable tubular member 126. Pins, 129a and 129b, coupled to the shoe 128 and the lower portion 126c of the expandable tubular member 126 prevent disengagement of the threaded connections, 126d and 128a, of the expandable tubular member and shoe. A conventional one-way poppet valve 130 is movably coupled to the shoe 128 and includes a valve element 130a for controllably sealing an opening of the internal passage 128c of the shoe. In an exemplary embodiment, the one-way poppet valve 130 only permits fluidic materials to be exhausted from the apparatus 100.

A threaded connection 132a at an end of a tubular body 132 that defines an internal passage 132b, having a plug valve seat 132ba, upper flow ports, 132c and 132d, and lower flow ports, 132e and 132f, and includes an external flange 132g for sealingly engaging the interior surface of the expandable tubular member 126, external splines 132h for mating with and engaging the internal splines 120g of the tubular support 120, and an internal annular recess 132i is coupled to the threaded connection 128g of the shoe 128. Another end of the tubular body 132 is received within an annulus defined between the interior surface of the other end of the tubular support 120 and the exterior surface of the tubular stinger 124, and sealingly engages the interior surface of the tubular support 120. An annular passage 133 is further defined between the interior surface of the other end of the tubular body 132 and the exterior surface of the tubular stinger 124.

A sliding sleeve valve 134 is movably received and supported within the internal passage 132b of the tubular body 132 that defines an internal passage 134a and radial passages, 134b and 134c, and includes collet fingers 134d at one end positioned within the annular recess 132i of the tubular body for releasably engaging the external flange 124d of the tubular stinger 124. The sliding sleeve valve 134 sealingly engages the internal surface of the internal passage 132b of the tubular body 132, and blocks the upper flow ports, 132c and 132d, of the tubular body. A valve guide pin 135 is coupled to the tubular body 132 for engaging the collet fingers 134d of the sliding sleeve valve 134 and thereby guiding and limiting the movement of the sliding sleeve valve.

During operation, as illustrated in FIGS. 4, 4a, 4b, 4c, and 4d, the apparatus 100 is positioned within a preexisting structure such as, for example, the wellbore 36 that traverses the subterranean formation 38. In an exemplary embodiment, during or after the positioning of the apparatus 100 within the wellbore 36, fluidic materials 140 may be circulated through and out of the apparatus into the wellbore 36 though the internal passages 114a, 112a, 120b, 124b, 134a, 132b, 128b, 128c, 128d, 128e, and 128f.

In an exemplary embodiment, as illustrated in FIGS. 5, 5a, 5b, 5c, and 5d, during operation of the apparatus 100, a conventional plug valve element 142 may then be injected into the apparatus through the passages 114a, 112a, 120b, 124b, 134a, and 132b until the plug valve element is seated in the plug seat 132ba of the internal passage of the tubular body 132. As a result, the flow of fluidic materials through the lower portion of the internal passage 132b of the tubular body 132 is blocked. Continued injection of fluidic materials 140 into the apparatus 100, following the seating of the plug valve element 142 in the plug seat 132ba of the internal passage of the tubular body 132, pressurizes the internal annular passage 135 and thereby causes the rupture discs, 122a and 122b, to be ruptured thereby opening the internal passages, 120c and 120d, of the tubular support 120. As a result, fluidic materials 140 are then conveyed through the internal passages, 120c and 120d, thereby pressurizing a region within the apparatus 100 below the tubular expansion cone 118. As a result, the tubular support 112, tubular support 114, tubular support 116, tubular expansion cone 118, tubular support 120, and tubular stinger 124 are displaced upwardly in the direction 144 relative to the expandable tubular member 126, shoe 128, tubular body 132, and sliding sleeve valve 134 thereby radially expanding and plastically deforming the expandable tubular member.

During the continued upward displacement of the tubular support 112, tubular support 114, tubular support 116, tubular expansion cone 118, tubular support 120, and tubular stinger 124 in the direction 144 relative to the expandable tubular member 126, shoe 128, tubular body 132, and sliding sleeve valve 134, the upward movement of the sliding sleeve valve is prevented by the operation of the valve guide pin 135. Consequently, at some point, the collet fingers 134d of the sliding sleeve valve 134 disengage from the external flange 124d of the tubular stinger 124.

In an exemplary embodiment, as illustrated in FIGS. 6, 6a, 6b, 6c, and 6d, during operation of the apparatus 100, before or after radially expanding and plastically deforming the expandable tubular member 126, the tubular support 112, tubular support 114, tubular support 116, tubular expansion cone 118, tubular support 120, and tubular stinger 124 are displaced downwardly in the direction 146 relative to the expandable tubular member 126, shoe 128, tubular body 132, and sliding sleeve valve 134 by, for example, setting the apparatus down onto the bottom of the wellbore 36. As a result, the end of the tubular body 132 that is received within the annulus defined between the interior surface of the other end of the tubular support 120 and the exterior surface of the tubular stinger 124 and that sealingly engages the interior surface of the tubular support 120 is displaced upwardly relative to the tubular support and tubular stinger thereby preventing fluidic materials from passing through the annular passage 133 into the radial passages, 120c and 120d, of the tubular support. Furthermore, as a result, the other end of the tubular stinger 124 impacts and displaces the sliding sleeve valve 134 downwardly in the direction 148 thereby aligning the internal passages, 132c and 132d, of the tubular body 132, with the internal passages, 134b and 134c, respectively, of the sliding sleeve valve. A hardenable fluidic sealing material 150 may then be injected into the apparatus 100 through the internal passages 114a, 112a, 120b, 124b, and 134a, into and through the internal passages 132c and 132d and 134b and 134c, into and through an annulus 152 defined between the interior of the expandable tubular member 126 and the exterior of the tubular body 132, and then out of the apparatus through the internal passages 132e and 132f of the tubular body and the internal passages 128b, 128c, 128d, 128e, and 128f of the shoe 128 into the annulus between the exterior surface of the expandable tubular member and the interior surface of the wellbore 36. As a result, an annular body of a hardenable fluidic sealing material such as, for example, cement is formed within the annulus between the exterior surface of the expandable tubular member 126 and the interior surface of the wellbore 36. Before, during, or after the curing of the annular body of the hardenable fluidic sealing material, the apparatus may then be operated as described above with reference to FIG. 5 to radially expand and plastically deform the expandable tubular member 126.

Referring to FIGS. 7, 7a, 7b, 7c, 7d and 7e, an exemplary embodiment of an apparatus 200 for radially expanding and plastically deforming a tubular member includes a tubular support 212 that defines a internal passage 212a and includes a threaded connection 212b at one end and a threaded connection 212c at another end. In an exemplary embodiment, during operation of the apparatus 200, a threaded end of a conventional tubular support member 214 that defines a passage 214a may be coupled to the threaded connection 212b of the tubular support member 212.

An end of a tubular support 216 that defines an internal passage 216a and radial passages, 216b and 216c, and includes an external annular recess 216d, an external flange 216e, and an internal flange 216f is coupled to the other end of the tubular support 212. A tubular expansion cone 218 that includes a tapered external expansion surface 218a is received within and is coupled to the external annular recess 216d of the tubular support 216 and an end of the tubular expansion cone abuts an end face of the external sleeve 216e of the tubular support.

A threaded connection 220a of an end of a tubular support 220 that defines an internal passage 220b and radial passages, 220c and 220d, and includes a threaded connection 220e, an external flange 220f, and internal splines 220g at another end is coupled to the threaded connection 212c of the other end of the tubular support 212. In an exemplary embodiment, the external flange 220f of the tubular support 220 abuts the internal flange 216f of the tubular support 216. Rupture discs, 222a and 222b, are received and mounted within the radial passages, 220c and 220d, respectively, of the tubular support 220.

A threaded connection 224a of an end of a tubular stinger 224 that defines an internal passage 224b and includes an external annular recess 224c and an external flange 224d at another end is coupled to the threaded connection 220e of the tubular support 220. An expandable tubular member 226 that defines an internal passage 226a for receiving the tubular supports 212, 214, 216, and 220 mates with and is supported by the external expansion surface 218a of the tubular expansion cone 218 that includes an upper portion 226b having a smaller inside diameter and a lower portion 226c having a larger inside diameter and a threaded connection 226d.

A threaded connection 228a of a shoe 228 that defines internal passages, 228b, 228c, and 228d, and includes a threaded connection 228e at one end and a threaded connection 228f at another end is coupled to the threaded connection 226d of the lower portion 226c of the expandable tubular member 226. Pins, 230a and 230b, coupled to the shoe 228 and the lower portion 226c of the expandable tubular member 226 prevent disengagement of the threaded connections, 226d and 228a, of the expandable tubular member and shoe. A threaded connection 232a of a shoe insert 232 that defines internal passages 232b and 232c is coupled to the threaded connection 228f of the shoe 228. In an exemplary embodiment, the shoe 228 and/or the shoe insert 232 are fabricated from composite materials in order to reduce the weight and cost of the components.

A conventional one-way poppet valve 234 is movably coupled to the shoe 228 and includes a valve element 234a for controllably sealing an opening of the internal passage 228c of the shoe. In an exemplary embodiment, the one-way poppet valve 234 only permits fluidic materials to be exhausted from the apparatus 200.

A threaded end 236a of a tubular plug seat 236 that defines an internal passage 236b having a plug seat 236ba and lower flow ports, 236c and 236d, is coupled to the threaded connection 228e of the shoe 228. In an exemplary embodiment, the tubular plug seat 236 is fabricated from aluminum in order to reduce weight and cost of the component. A tubular body 238 defines an internal passage 238a, lower flow ports, 238b and 238c, and upper flow ports, 238d and 238e, and includes an internal annular recess 238f at one end that mates with and receives the other end of the tubular plug seat 236, and an internal annular recess 238g and an external flange 238h for sealingly engaging the interior surface of the expandable tubular member 226 at another end. In an exemplary embodiment, the tubular body 238 is fabricated from a composite material in order to reduce weight and cost of the component.

In an exemplary embodiment, as illustrated in FIG. 7a, the tubular body 238 further defines longitudinal passages, 238i and 238j, for fluidicly coupling the upper and lower flow ports, 238d and 238e and 238b and 238c, respectively.

One or more retaining pins 240 couple the other end of the tubular plug seat 236 to the internal annular recess 238f of the tubular body.

An end of a sealing sleeve 242 that defines an internal passage 242a and upper flow ports, 242b and 242c, and includes external splines 242d that mate with and receive the internal splines 220g of the tubular support 220 and an internal annular recess 242e is received within and mates with the internal annular recess 238g at the other end of the tubular body. The other end of the sealing sleeve 242 is received within an annulus defined between the interior surface of the other end of the tubular support 220 and the exterior surface of the tubular stinger 224, and sealingly engages the interior surface of the other end of the tubular support 220. In an exemplary embodiment, the sealing sleeve 242 is fabricated from aluminum in order to reduce weight and cost of the component. One or more retaining pins 243 coupled the end of the sealing sleeve 242 to the internal annular recess 238g at the other end of the tubular body 238. An annular passage 244 is further defined between the interior surface of the other end of the tubular body sealing sleeve 242 and the exterior surface of the tubular stinger 224.

A sliding sleeve valve 246 is movably received and supported within the internal passage 242a of the sealing sleeve 242 that defines an internal passage 246a and radial passages, 246b and 246c, and includes collet fingers 246d at one end positioned within the annular recess 242e of the sealing sleeve for releasably engaging the external flange 224d of the tubular stinger 224. The sliding sleeve valve 246 sealingly engages the internal surface of the internal passage 242a of the sealing sleeve 242, and blocks the upper flow ports, 242b and 242c and 238d and 238e, of the sealing sleeve and the tubular body, respectively. A valve guide pin 248 is coupled to the sealing sleeve 242 for engaging the collet fingers 246d of the sliding sleeve valve 246 and thereby guiding and limiting the movement of the sliding sleeve valve.

During operation, as illustrated in FIGS. 7, 7a, 7b, 7c, 7d and 7e, the apparatus 200 is positioned within a preexisting structure such as, for example, the wellbore 36 that traverses the subterranean formation 38. In an exemplary embodiment, during or after the positioning of the apparatus 200 within the wellbore 36, fluidic materials 250 may be circulated through and out of the apparatus into the wellbore 36 though the internal passages 214a, 212a, 220b, 224b, 246a, 242a, 238a, 236b, 228b, 228c, 228d, 232b, and 232c.

In an exemplary embodiment, as illustrated in FIGS. 8, 8a, 8b, 8c, and 8d, during operation of the apparatus 200, a conventional plug valve element 252 may then be injected into the apparatus through the passages 214a, 212a, 220b, 224b, 246a, 242a, 238a, and 236b until the plug valve element is seated in the plug seat 236ba of the internal passage 236b of the tubular plug seat 236. As a result, the flow of fluidic materials through the lower portion of the internal passage 236b of the tubular plug seat 236 is blocked. Continued injection of fluidic materials 250 into the apparatus 200, following the seating of the plug valve element 252 in the plug seat 236ba of the internal passage 236b of the tubular plug seat 236, pressurizes the internal annular passage 244 and thereby causes the rupture discs, 222a and 222b, to be ruptured thereby opening the internal passages, 220c and 220d, of the tubular support 220. As a result, fluidic materials 250 are then conveyed through the internal passages, 220c and 220d, thereby pressurizing a region within the apparatus 200 below the tubular expansion cone 218. As a result, the tubular support 212, tubular support 214, tubular support 216, tubular expansion cone 218, tubular support 220, and tubular stinger 224 are displaced upwardly in the direction 254 relative to the expandable tubular member 226, shoe 228, shoe insert 232, tubular plug seat 236, tubular body 238, sealing sleeve 242, and sliding sleeve valve 236 thereby radially expanding and plastically deforming the expandable tubular member.

During the continued upward displacement of the tubular support 212, tubular support 214, tubular support 216, tubular expansion cone 218, tubular support 220, and tubular stinger 224 in the direction 254 relative to the expandable tubular member 226, shoe 228, shoe insert 232, tubular plug seat 236, tubular body 238, sealing sleeve 242, and sliding sleeve valve 236, the upward movement of the sliding sleeve valve is prevented by the operation of the valve guide pin 248. Consequently, at some point, the collet fingers 246d of the sliding sleeve valve 246 disengage from the external flange 224d of the tubular stinger 224.

In an exemplary embodiment, as illustrated in FIGS. 9, 9a, 9b, 9c, and 9d, during operation of the apparatus 200, before or after radially expanding and plastically deforming the expandable tubular member 226, the tubular support 212, tubular support 214, tubular support 216, tubular expansion cone 218, tubular support 220, and tubular stinger 224 are displaced downwardly in the direction 256 relative to the expandable tubular member 226, shoe 228, shoe insert 232, tubular plug seat 236, tubular body 238, sealing sleeve 242, and sliding sleeve valve 236 by, for example, setting the apparatus down onto the bottom of the wellbore 36. As a result, the end of the sealing sleeve 242 that is received within the annulus defined between the interior surface of the other end of the tubular support 220 and the exterior surface of the tubular stinger 224 and that sealingly engages the interior surface of the tubular support 220 is displaced upwardly relative to the tubular support and tubular stinger thereby preventing fluidic materials from passing through the annular passage 244 into the radial passages, 220c and 220d, of the tubular support. Furthermore, as a result, the other end of the tubular stinger 224 impacts and displaces the sliding sleeve valve 246 downwardly in the direction 258 thereby aligning the internal passages, 238d and 238e and 242b and 242c, of the tubular body 238 and sealing sleeve 242, respectively, with the internal passages, 246b and 246c, respectively, of the sliding sleeve valve. A hardenable fluidic sealing material 260 may then be injected into the apparatus 200 through the internal passages 214a, 212a, 220b, 224b, and 246a, into and through the internal passages 238d, 238e, 242b, 242c, 246b and 246c, into and through the longitudinal grooves, 238i and 238j, into and through the internal passages, 236a, 236b, 238b and 238c, and then out of the apparatus through the internal passages 228b, 228c, 228d of the shoe 228f and 232b and 232c of the shoe insert 232 into the annulus between the exterior surface of the expandable tubular member 226 and the interior surface of the wellbore 36. As a result, an annular body of a hardenable fluidic sealing material such as, for example, cement is formed within the annulus between the exterior surface of the expandable tubular member 226 and the interior surface of the wellbore 36. Before, during, or after the curing of the annular body of the hardenable fluidic sealing material, the apparatus may then be operated as described above with reference to FIG. 8 to radially expand and plastically deform the expandable tubular member 226.

In an exemplary embodiment, as illustrated in FIGS. 10, 10a and 10b, an exemplary embodiment of a flow control device 280 includes a tubular support 282 that defines an internal passage 282a and includes an internal threaded connection 282b at one end, an external threaded connection 282c at another end, and an external threaded connection 282d between the ends of the tubular support 282. The tubular support 282 defines a plurality of generally circumferentially-spaced flow ports 282ea, 282eb, 282ec and 282ed at one axial location along the support 282, and a plurality of generally circumferentially-spaced flow ports 282fa, 282fb, 282fc and 282fd at another axial location along the support 282. The tubular support 282 further includes an internal shoulder 282g, counterbores 282ha and 282hb, and axially-spaced sealing elements 282ia, 282ib, 282ic and 282id, each of which extends within a respective annular channel formed in the exterior surface of the tubular support 282. In an exemplary embodiment, each of the sealing elements 282ia, 282ib, 282ic and 282id is an o-ring.

A sliding sleeve 284 that defines a longitudinally-extending internal passage 284a and a plurality of generally circumferentially-spaced flow ports 284ba, 284bb, 284bc and 284bd, and includes longitudinally-extending channels 284ca and 284cb, generally circumferentially-spaced bores 284da, 284db, 284dc and 284dd, axially-spaced sealing elements 284ea, 284eb, 284ec, 284ed, 284ee and 284ef, and a plug seat 284f, is received within the passage 282a, sealingly engaging the interior surface of the tubular support 282. In an exemplary embodiment, each of the sealing elements 284ea, 284eb, 284ec, 284ed, 284ee and 284ef is an o-ring that extends in an annular channel formed in the exterior surface of the sliding sleeve 284. The sliding sleeve 284 is adapted to move relative to, and slide against the interior surface of, the tubular support 282 under conditions to be described.

Circumferentially-spaced pins 286a, 286b, 286c and 286d extend through the tubular support 282 and into the bores 284da, 284db, 284dc and 284dd, respectively, thereby locking the position of the sliding sleeve 284 relative to the tubular support 282. Protrusions such as, for example, fasteners 288a and 288b, extend through the counterbores 282ha and 282hb, respectively, of the tubular support 282 and into the channels 284ca and 284cb, respectively, to guide and limit the movement of the sliding sleeve 284 relative to the tubular support 282. Moreover, the pins 286a, 286b, 286c and 286d, and the fasteners 288a and 288b, are adapted to prevent the sliding sleeve 284 from rotating about its longitudinal axis, relative to the tubular support 282.

A one-way poppet valve 290 is coupled to the tubular support 282 and includes a movable valve element 290a for controllably sealing an opening of the internal passage 282a of the tubular support 282. In an exemplary embodiment, the one-way poppet valve 290 only permits fluidic materials to flow through the internal passage 282a of the tubular support 282 in one direction. In an exemplary embodiment, the one-way poppet valve 290 only permits fluidic materials to flow through the internal passage 282a of the tubular support 282 in the downward direction as viewed in FIG. 10a.

An internal threaded connection 292a of an outer sleeve 292 that defines an internal passage 292b through which the tubular support 282 extends and includes an internal annular recess 292c, is coupled to the external threaded connection 282d of the tubular support 282. As a result, the tubular support 282 is coupled to the outer sleeve 292, with the sealing elements 282ia and 282ib sealingly engaging the interior surface of the outer sleeve 292 above the internal annular recess 292c, and the sealing elements 282ic and 282id sealingly engaging the interior surface of the outer sleeve 292 below the internal annular recess 292c. An annular region 294 is defined between the exterior surface of the tubular support 282 and the interior surface of the outer sleeve 292 defined by the internal annular recess 292c.

Referring to FIGS. 11, 11a, 11b, 11c, and 11d, an exemplary embodiment of an apparatus 300 for radially expanding and plastically deforming a tubular member includes a tubular support 312 that defines a internal passage 312a and includes a threaded connection 312b at one end and a threaded connection 312c at another end. In an exemplary embodiment, during operation of the apparatus 300, a threaded end of a tubular support member 314 that defines a passage 314a may be coupled to the threaded connection 312b of the tubular support member 312.

An end of a tubular support 316 that defines an internal passage 316a and radial passages, 316b and 316c, and includes an external annular recess 316d, an external sleeve 316e, and an internal flange 316f is coupled to the other end of the tubular support 312. A tubular expansion cone 318 that includes a tapered external expansion surface 318a is received within and is coupled to the external annular recess 316d of the tubular support 316 and an end of the tubular expansion cone 318 abuts an end face of the external sleeve 316e of the tubular support 316.

A threaded connection 320a of an end of a tubular support 320 that defines an internal passage 320b having an enlarged-inside-diameter portion 320ba, defines radial passages, 320c and 320d, and includes an external flange 320e, and internal splines 320f at another end is coupled to the threaded connection 312c of the other end of the tubular support 312. In an exemplary embodiment, the external flange 320e of the tubular support 320 abuts the internal flange 316f of the tubular support 316. Rupture discs, 322a and 322b, are received and mounted within the radial passages, 320c and 320d, respectively, of the tubular support 320.

An end of a tubular support 324 defining an internal passage 324a and including an external flange 324b, an external threaded connection 324c at another end, and external splines 324d for mating with and engaging the internal splines 320f of the tubular support 320, extends within the enlarged-inside-diameter portion 320ba of the passage 320b of the tubular support 320, and sealingly engages an interior surface of the tubular support 320. The external threaded connection 324c of the tubular support 324 is coupled to the internal threaded connection 282b of the tubular support 282 of the flow control device 280 so that the other end of the tubular support 324 extends within the internal passage 282a of the tubular support 282. In an exemplary embodiment, the other end of the tubular support 324 is proximate an end of the sliding sleeve 284 of the flow control device 280. In an exemplary embodiment, the other end of the tubular support 324 abuts the end of the sliding sleeve 284 of the flow control device 280.

An expandable tubular member 326 that defines an internal passage 326a for receiving the tubular supports 312, 314, 316, and 320 mates with and is supported by the external expansion surface 318a of the tubular expansion cone 318 that includes an upper portion 326b having a smaller inside diameter and a lower portion 326c having a larger inside diameter and a threaded connection 326d.

A ring 327 through which the other end of the tubular support 324 extends abuts, and is disposed between, the external flange 324b of the tubular support 324 and the end of the tubular support 282 of the flow control device 280 proximate the internal threaded connection 282b. The ring 327 sealingly engages an exterior surface of the tubular support 324 and an interior surface of the expandable tubular member 326.

The external threaded connection 282c of the tubular support 282 of the flow control device 282 is coupled to an internal threaded connection 328a of a shoe 328 that defines internal passages, 328b, 328c, 328d, 328e, 328f, and 328g, and includes another threaded connection 328h that is coupled to the threaded connection 326d of the lower portion 326c of the expandable tubular member 326. As a result, the flow control device 282 is coupled to and extends between the tubular support 324 and the shoe 328. In an exemplary embodiment, the one-way poppet valve 290 of the flow control device 280 only permits fluidic materials to be exhausted from the apparatus 300.

During operation, in an exemplary embodiment, as illustrated in FIGS. 11, 11a, 11b, 11c and 11d, the apparatus 300 is positioned within a preexisting structure such as, for example, the wellbore 36 that traverses the subterranean formation 38. The pins 286a, 286b, 286c and 286d of the flow control device 280 lock the position of the sliding sleeve 284, relative to the tubular support 282, as described above. As a result, the flow ports 284ba, 284bb, 284bc and 284bd of the sliding sleeve 284 are aligned with the flow ports 282ea, 282eb, 282ec and 282ed, respectively, of the tubular support 282 so that the passage 284a of the sliding sleeve 284 is fluidicly coupled to the annular region 294, which, as illustrated in FIG. 11d, is fluidicly coupled to the portion of the internal passage 282a of the tubular support 282 below the sliding sleeve 284 via the flow ports 282fa, 282fb, 282fc and 282fd.

In an exemplary embodiment, as illustrated in FIGS. 12, 12a, 12b, 12c and 12d, during or after the positioning of the apparatus 300 within the wellbore 36, fluidic materials 330 may be circulated through and out of the apparatus 300 into the wellbore 36 through at least the internal passages 314a, 312a, 320b, 324a and 284a, the flow ports 284ba, 284bb, 284bc and 284bd, the flow ports 282ea, 282eb, 282ec and 282ed aligned with the flow ports 284ba, 284bb, 284bc and 284bd, respectively, the annular region 294, the flow ports 282fa, 282fb, 282fc and 282fd, the portion of the internal passage 282a below the sliding sleeve 284, and the internal passages 328b, 328c, 328d, 328e, 328f, and 328g. In addition, in an exemplary embodiment, the fluidic materials 330 also flow through the portion of the internal passage 282a above the sliding sleeve 284. As a result of the circulation of the fluidic materials 330 through and out of the apparatus 300, the fluidic materials 330 are injected into the annulus between the exterior surface of the expandable tubular member 326 and the interior surface of the wellbore 36.

In an exemplary embodiment, as illustrated in FIGS. 13, 13a, 13b, 13c, and 13d, during the injection of the fluidic materials 330 into the annulus between the exterior surface of the expandable tubular member 326 and the interior surface of the wellbore 36, a plug valve element 332 may then be injected into the apparatus 300 through the passages 314a, 312a, 320b, 324a and 284a until the plug valve element 332 is seated in the plug seat 284f of the sliding sleeve 284. As a result, the flow of the fluidic materials 330 through the internal passage 284a and the flow ports 284ba, 284bb, 284bc and 284bd of the sliding sleeve 284 of the flow control device 280 is blocked. Continued injection of the fluidic materials 330 into the apparatus 300, following the seating of the plug valve element 332 in the plug seat 284f of the sliding sleeve 284, pressurizes the passages 314a, 320b and 324a, thereby causing locking pins 286a, 286b, 286c and 286d to shear and the plug valve element 332 and the sliding sleeve 284 to move downward, relative to the tubular support 282 of the flow control device 280. In an exemplary embodiment, the fasteners 288a and 288b guide the axial movement of the sliding sleeve 284, and continue to generally prevent any rotation of the sliding sleeve 284 about its longitudinal axis and relative to the tubular support 282. In an exemplary embodiment, the plug valve element 332 and the sliding sleeve 284 move downward, relative to the tubular support 282, until the fasteners 288a and 288b contact respective surfaces of the sliding sleeve 284 defined by respective upper ends of the channels 284ca and 284cb, thereby limiting the range of movement of the sliding sleeve 284 relative to the tubular support 282. As a result of the downward movement of the sliding sleeve 284, the flow ports 284ba, 284bb, 284bc and 284bd of the sliding sleeve 284 are no longer aligned with the flow ports 282ea, 282eb, 282ec and 282ed, respectively, of the tubular support 282, and the annular region 294 is no longer fluidicly coupled to the portion of the passage 282a below the sliding sleeve 284 since the exterior surface of the sliding sleeve 284 covers, or blocks, the flow ports 282fa, 282fb, 282fc and 282fd. As a result of the seating of the plug valve element 332 in the plug seat 284f, the absence of any alignment between the flow ports 284ba, 284bb, 284bc and 284bd and the flow ports 282ea, 282eb, 282ec and 282ed, respectively, and/or the blocking of the ports 282fa, 282fb, 282fc and 282fd, the passages 314a, 312a, 320b, 324a and 284a are fluidicly isolated from the portion of the passage 282a below the sliding sleeve 284 and from the valve 290. In an exemplary embodiment, if the plug valve element 332 is abraded and/or damaged by, for example, any debris in, for example, the apparatus 300 and/or the wellbore 36, thereby compromising the sealing engagement between the plug valve element 332 and the plug seat 284f to at least some degree, the fluidic isolation between the passages 314a, 312a, 320b, 324a and 284a and the valve 290 and the portion of the passage 282a below the sliding sleeve 284 is still maintained by the absence of any alignment between the flow ports 284ba, 284bb, 284bc and 284bd and the flow ports 282ea, 282eb, 282ec and 282ed, respectively, and/or the blocking of the ports 282fa, 282fb, 282fc and 282fd, thereby maintaining the pressurization of the passages 314a, 312a, 320b, 324a and 284a. In an exemplary embodiment, the sealing engagement between the exterior surface of the sliding sleeve 284 and the interior surface of the tubular support 282 is maintained because the sealing elements 284ea, 284eb, 284ec, 284ed, 284ee and 284ef are a part of the flow control device 280, and generally are not exposed to debris and/or any other potential causes of abrasion and/or damage in, for example, the wellbore 36 and/or the remainder of the apparatus 300.

Continued injection of the fluidic materials 330 into the apparatus, following the general prevention of further axial movement of the sliding sleeve 284 relative to the tubular support 282, continues to pressurize the passages 314a, 320b and 324a, thereby causing the rupture discs 322a and 322b to be ruptured, thereby opening the passages 320c and 320d of the tubular support 320. As a result, the fluidic materials 330 are then conveyed through the passages 320c and 320d, and the passages 316b and 316c, thereby pressurizing a region within the apparatus 300 below the tubular expansion cone 318. As a result, the tubular support 312, the tubular support 314, the tubular support 316, the tubular expansion cone 318 and the tubular support 320 are displaced upwardly in a direction 334, relative to the tubular support 324, the expandable tubular member 326, the ring 327, the shoe 328 and the flow control device 280, thereby radially expanding and plastically deforming the expandable tubular member 326.

In an exemplary embodiment, with continuing reference to FIGS. 12, 12a, 12b, 12c, 12d, 13, 13a, 13b, 13c and 13d, during operation of the apparatus 300, before radially expanding and plastically deforming the expandable tubular member 326, and before the pins 286a, 286b, 286c and 286d are sheared, that is, when the flow control device 280 is in the configuration as illustrated in FIGS. 12, 12a, 12b, 12c and 12d, the fluidic materials 330 may include a hardenable fluidic sealing material so that the hardenable fluidic sealing material is circulated through at least the internal passages 314a, 312a, 320b, 324a and 284a, the flow ports 284ba, 284bb, 284bc and 284bd, the flow ports 282ea, 282eb, 282ec and 282ed aligned with the flow ports 284ba, 284bb, 284bc and 284bd, respectively, the annular region 294, the flow ports 282fa, 282fb, 282fc and 282fd, the portion of the internal passage 282a below the sliding sleeve 284, and the internal passages 328b, 328c, 328d, 328e, 328f, and 328g and out of the apparatus 300, thereby injecting the hardenable fluidic sealing material into the annulus between the exterior surface of the expandable tubular member 326 and the interior surface of the wellbore 36. As a result, an annular body of a hardenable fluidic sealing material such as, for example, cement, is formed within the annulus between the exterior surface of the expandable tubular member 326 and the interior surface of the wellbore 36. Before, during, or after the curing of the annular body of the hardenable fluidic sealing material, the apparatus 300 may then be operated as described above with reference to FIGS. 13, 13a, 13b, 13c and 13d to radially expand and plastically deform the expandable tubular member 326.

Referring to FIGS. 14, 14a, 14b, 14c, and 14d, an exemplary embodiment of an apparatus 400 for radially expanding and plastically deforming a tubular member includes a tubular support 412 that defines a internal passage 412a and includes a threaded connection 412b at one end and a threaded connection 412c at another end. In an exemplary embodiment, during operation of the apparatus 400, a threaded end of a tubular support member 414 that defines a passage 414a may be coupled to the threaded connection 412b of the tubular support member 412.

An end of a tubular support 416 that defines an internal passage 416a and radial passages, 416b and 416c, and includes an external annular recess 416d, an external sleeve 416e, and an internal flange 416f is coupled to the other end of the tubular support 412. A tubular expansion cone 418 that includes a tapered external expansion surface 418a is received within and is coupled to the external annular recess 416d of the tubular support 416 and an end of the tubular expansion cone 418 abuts an end face of the external sleeve 416e of the tubular support 416.

A threaded connection 420a of an end of a tubular support 420 that defines an internal passage 420b having an enlarged-inside-diameter portion 420ba, defines radial passages, 420c and 420d, and includes an external flange 420e, and internal splines 420f at another end is coupled to the threaded connection 412c of the other end of the tubular support 412. In an exemplary embodiment, the external flange 420e of the tubular support 420 abuts the internal flange 416f of the tubular support 416. Rupture discs, 422a and 422b, are received and mounted within the radial passages, 420c and 420d, respectively, of the tubular support 420.

An end of a tubular support 424 defining an internal passage 424a and including an external flange 424b, an external threaded connection 424c at another end, and external splines 424d for mating with and engaging the internal splines 420f of the tubular support 420, extends within the enlarged-inside-diameter portion 420ba of the passage 420b of the tubular support 420, and sealingly engages an interior surface of the tubular support 420.

A flow control device 426 is coupled to the tubular support 424. More particularly, an internal threaded connection 428a at one end of a tubular support 428 of the flow control device 426 defining an internal passage 428b, a plurality of circumferentially-spaced flow ports 428ca and 428cb at one axial location therealong, and a plurality of circumferentially-spaced flow ports 428da, 428db and 428dc at another axial location therealong, and including an external threaded connection 428e at another end thereof, and an internal shoulder 428f, is coupled to the external threaded connection 424c of the tubular support 424 so that the other end of the tubular support 424 extends within the internal passage 428b of the tubular support 428.

The flow control device 426 further includes a sliding sleeve 430 defining a longitudinally-extending internal passage 430a and a plurality of circumferentially-spaced flow ports 430ba and 430bb, and including generally circumferentially-spaced bores 430ca and 430cb, axially-spaced sealing elements 430da, 430db and 430dc, and a plug seat 430e. The sliding sleeve 430 is received within the internal passage 428b of the tubular support 428, sealingly engaging the interior surface of the tubular support 428. In an exemplary embodiment, each of the sealing elements 430da, 430db and 430dc is an o-ring that extends within an annular channel formed in the exterior surface of the sliding sleeve 430. The sliding sleeve 430 is adapted to move relative to, and slide against the interior surface of, the tubular support 428 under conditions to be described.

Circumferentially-spaced pins 432a and 432b extend through the tubular support 428 and into the bores 430ca and 430cb, respectively, thereby locking the position of the sliding sleeve 430 relative to the tubular support 428 and preventing rotation of the sliding sleeve 430 relative to the tubular support 428.

A one-way poppet valve 434 is coupled to the tubular support 428 and includes a movable valve element 434a for controllably sealing an opening of the internal passage 428b of the tubular support 428. In an exemplary embodiment, the one-way poppet valve 434 only permits fluidic materials to flow through the internal passage 428b of the tubular support 428 in one direction. In an exemplary embodiment, the one-way poppet valve 434 only permits fluidic materials to flow through the internal passage 428b of the tubular support 428 in the downward direction as viewed in FIG. 14D.

As noted above, the internal threaded connection 428a at one end of a tubular support 428 is coupled to the external threaded connection 424c of the tubular support 424 so that the other end of the tubular support 424 extends within the internal passage 428b of the tubular support 428. In an exemplary embodiment, the other end of the tubular support 424 is proximate an end of the sliding sleeve 430 of the flow control device 426. In an exemplary embodiment, the other end of the tubular support 424 abuts the end of the sliding sleeve 430 of the flow control device 426.

An expandable tubular member 436 that defines an internal passage 436a for receiving the tubular supports 412, 414, 416, and 420 mates with and is supported by the external expansion surface 418a of the tubular expansion cone 418 that includes an upper portion 436b having a smaller inside diameter and a lower portion 436c having a larger inside diameter and an internal threaded connection 436d.

A ring 438 through which the other end of the tubular support 424 extends abuts, and is disposed between, the external flange 424b of the tubular support 424 and the end of the tubular support 428 of the flow control device 426 proximate the internal threaded connection 428a. The ring 428 sealingly engages an exterior surface of the tubular support 424 and an interior surface of the expandable tubular member 436.

The external threaded connection 428e of the tubular support 428 of the flow control device 426 is coupled to an internal threaded connection 440a of a shoe 440 that defines internal passages, 440b, 440c, 440d, 440e, 440f, and 440g, and includes another threaded connection 440h that is coupled to the internal threaded connection 436d of the lower portion 436c of the expandable tubular member 436. As a result, the flow control device 426 is coupled to and extends between the tubular support 424 and the shoe 440. In an exemplary embodiment, the one-way poppet valve 434 of the flow control device 426 only permits fluidic materials to be exhausted from the apparatus 400.

An annular region 442 is radially defined between the exterior surface of the tubular support 428 of the flow control device 426 and the interior surface of the expandable tubular member 436, and is axially defined between the shoe 440 and the ring 438.

During operation, in an exemplary embodiment, as illustrated in FIGS. 14, 14a, 14b, 14c and 14d, the apparatus 400 is positioned within a preexisting structure such as, for example, the wellbore 36 that traverses the subterranean formation 38. The pins 432a and 432b of the flow control device 426 lock the position of the sliding sleeve 430, relative to the tubular support 428, as described above. As a result, the flow ports 430ba and 430bb of the sliding sleeve 430 are aligned with the flow ports 428ca and 428cb, respectively, of the tubular support 428 so that the passage 430a of the sliding sleeve 430 is fluidicly coupled to the annular region 442, which, as illustrated in FIG. 14d, is fluidicly coupled to the portion of the internal passage 428b of the tubular support 428 below the sliding sleeve 430 via the flow ports 428da, 428db and 428dc.

In an exemplary embodiment, as illustrated in FIGS. 15, 15a, 15b, 15c and 15d, during or after the positioning of the apparatus 400 within the wellbore 36, fluidic materials 444 may be circulated through and out of the apparatus 400 into the wellbore 36 through at least the internal passages 414a, 412a, 420b, 424a and 430a, the flow ports 430ba and 430bb, the flow ports 428ca and 428cb aligned with the flow ports 430ba and 430bb, respectively, the annular region 442, the flow ports 428da, 428db and 428dc, the portion of the internal passage 428b below the sliding sleeve 430, and the internal passages 440b, 440c, 440d, 440e, 440f, and 440g. In addition, in an exemplary embodiment, the fluidic materials 444 also flow through the portion of the internal passage 428b above the sliding sleeve 430. As a result of the circulation of the fluidic materials 444 through and out of the apparatus 400, the fluidic materials 444 are injected into the annulus between the exterior surface of the expandable tubular member 436 and the interior surface of the wellbore 36.

In an exemplary embodiment, as illustrated in FIGS. 16, 16a, 16b, 16c, and 16d, during the injection of the fluidic materials 444 into the annulus between the exterior surface of the expandable tubular member 436 and the interior surface of the wellbore 36, a plug valve element 446 may then be injected into the apparatus 400 through the passages 414a, 412a, 420b, 424a and 430a until the plug valve element 446 is seated in the plug seat 430e of the sliding sleeve 430. As a result, the flow of the fluidic materials 444 through the internal passage 430a and the flow ports 430ba and 430bb of the sliding sleeve 430 of the flow control device 426 is blocked. Continued injection of the fluidic materials 444 into the apparatus 400, following the seating of the plug valve element 446 in the plug seat 430e of the sliding sleeve 430, pressurizes the passages 414a, 420b and 424a, thereby causing locking pins 432a and 432b to shear and the plug valve element 446 and the sliding sleeve 430 to move downward, relative to the tubular support 428 of the flow control device 426. The plug valve element 446 and the sliding sleeve 430 move downward, relative to the tubular support 428, until an end of the sliding sleeve 430 contacts the internal shoulder 428f of the tubular support 428, thereby limiting the range of movement of the sliding sleeve 430 relative to the tubular support 428. As a result of the downward movement of the sliding sleeve 430, the flow ports 430ba and 430bb of the sliding sleeve 430 are no longer aligned with the flow ports 428ca and 428cb, respectively, of the tubular support 428, and the annular region 442 is no longer fluidicly coupled to the portion of the passage 428b below the sliding sleeve 430 since the exterior surface of the sliding sleeve 430 covers, or blocks, the flow ports 428ca and 428cb. As a result of the seating of the plug valve element 446 in the plug seat 430e, the absence of any alignment between the flow ports 430ba and 430bb and the flow ports 428ca and 428cb, respectively, and/or the blocking of the ports 428ca and 428cb, the passages 414a, 412a, 420b, 424a and 430a are fluidicly isolated from the portion of the passage 428b below the sliding sleeve 430 and from the valve 434. In an exemplary embodiment, if the plug valve element 446 is abraded and/or damaged by, for example, any debris in, for example, the apparatus 400 and/or the wellbore 36, thereby compromising the sealing engagement between the plug valve element 446 and the plug seat 430e to at least some degree, the fluidic isolation between the passages 414a, 412a, 420b, 424a and 430a and the valve 434 and the portion of the passage 428b below the sliding sleeve 430 is still maintained by the absence of any alignment between the flow ports 430ba and 430bb and the flow ports 428ca and 428cb, respectively, and/or the blocking of the ports 428ca and 428cb, thereby maintaining the pressurization of the passages 414a, 412a, 420b, 424a and 430a. In an exemplary embodiment, the sealing engagement between the exterior surface of the sliding sleeve 430 and the interior surface of the tubular support 428 is maintained because the sealing elements 430da, 430db and 430dc are a part of the flow control device 426, and generally are not exposed to debris and/or any other potential causes of abrasion and/or damage in, for example, the wellbore 36 and/or the remainder of the apparatus 400.

Continued injection of the fluidic materials 444 into the apparatus 400, following the general prevention of further axial movement of the sliding sleeve 430 relative to the tubular support 428 continues to pressurize the passages 414a, 420b and 424a, thereby causing the rupture discs 422a and 422b to be ruptured, thereby opening the passages 420c and 420d of the tubular support 420. As a result, the fluidic materials 444 are then conveyed through the passages 420c and 420d, and the passages 416b and 416c, thereby pressurizing a region within the apparatus 400 below the tubular expansion cone 418. As a result, the tubular support 412, the tubular support 414, the tubular support 416, the tubular expansion cone 418 and the tubular support 420 are displaced upwardly in a direction 448, relative to the tubular support 424, the expandable tubular member 436, the ring 438, the shoe 440 and the flow control device 426, thereby radially expanding and plastically deforming the expandable tubular member 436.

In an exemplary embodiment, with continuing reference to FIGS. 15, 15a, 15b, 15c, 15d, 16, 16a, 16b, 16c and 16d, during operation of the apparatus 400, before radially expanding and plastically deforming the expandable tubular member 436, and before the pins 432a and 432b are sheared, that is, when the flow control device 426 is in the configuration as illustrated in FIGS. 15, 15a, 15b, 15c and 15d, the fluidic materials 444 may include a hardenable fluidic sealing material so that the hardenable fluidic sealing material is circulated through at least the internal passages 414a, 412a, 420b, 424a and 430a, the flow ports 430ba and 430bb, the flow ports 428ca and 428cb aligned with the flow ports 430ba and 430bb, respectively, the annular region 442, the flow ports 428da, 428db and 428dc, the portion of the internal passage 428b below the sliding sleeve 430, and the internal passages 440b, 440c, 440d, 440e, 440f, and 440g, and out of the apparatus 400, thereby injecting the hardenable fluidic sealing material into the annulus between the exterior surface of the expandable tubular member 436 and the interior surface of the wellbore 36. As a result, an annular body of a hardenable fluidic sealing material such as, for example, cement, is formed within the annulus between the exterior surface of the expandable tubular member 436 and the interior surface of the wellbore 36. Before, during, or after the curing of the annular body of the hardenable fluidic sealing material, the apparatus 400 may then be operated as described above with reference to FIGS. 16, 16a, 16b, 16c and 16d to radially expand and plastically deform the expandable tubular member 436.

In several exemplary embodiments, instead of, or in addition to the above-described methods, apparatuses and/or systems for radially expanding and plastically deforming an expandable tubular member, it is understood that the expandable tubular members 26, 126, 226, 326 and/or 436 may be radially expanded and plastically deformed using one or more other methods, apparatuses and/or systems, and/or any combination thereof. In several exemplary embodiments, instead of, or in addition to the above-described methods, apparatuses and/or systems for radially expanding and plastically deforming an expandable tubular member, the flow control devices 280 and/or 426 may be used with one or more other methods, apparatuses and/or systems for radially expanding and plastically deforming an expandable tubular member, and/or any combination thereof, and/or may be used with one or more other flow control methods, apparatuses and/or systems, and/or any combination thereof, in one or more other flow control applications.

An apparatus has been described that includes a flow control device comprising a tubular support defining a first internal passage and comprising one or more first flow ports; a sliding sleeve at least partially received within the first internal passage and sealingly engaging the tubular support, the sliding sleeve defining a second internal passage into which fluidic materials are adapted to be injected, the sliding sleeve comprising one or more second flow ports; a first position in which the first flow ports are aligned with respective ones of the second flow ports; and a second position in which the first flow ports are not aligned with the respective ones of the second flow ports. In an exemplary embodiment, the flow control device further comprises one or more pins extending into the sliding sleeve; wherein, when the sliding sleeve is in the first position, the one or more pins extend from the tubular support and into the sliding sleeve to maintain the sliding sleeve in the first position; and wherein, when the sliding sleeve is in the second position, the one or more pins are sheared to permit the sliding sleeve to move between the first and second positions. In an exemplary embodiment, the flow control device further comprises a valve coupled to the tubular support, the valve comprising a movable valve element for controllably sealing an opening of the first internal passage of the tubular support. In an exemplary embodiment, the apparatus comprises a plug valve element adapted to be seated in the second internal passage of the sliding sleeve of the flow control device. In an exemplary embodiment, the flow control device further comprises a plurality of axially-spaced sealing elements coupled to the sliding sleeve and sealingly engaging the tubular support; and wherein the second flow ports are axially positioned between two of the sealing elements. In an exemplary embodiment, the tubular support further comprises one or more third flow ports axially spaced from the one or more first flow ports. In an exemplary embodiment, the fluid control device further comprises an outer sleeve coupled to the tubular support so that an annular region is defined between the tubular support and the outer sleeve; wherein, when the sliding sleeve is in the first position, the annular region is fluidicly coupled to the second internal passage of the sliding sleeve via the first flow ports and the second flow ports aligned therewith, respectively; and wherein, when the sliding sleeve is in the second position, the annular region is fluidicly isolated from the second internal passage of the sliding sleeve. In an exemplary embodiment, the tubular support further comprises one or more third flow ports axially spaced from the one or more first flow ports; wherein, when the sliding sleeve is in the first position, a portion of the first internal passage of the tubular support is defined by the sliding sleeve; wherein, when the sliding sleeve is in the first position, the annular region is fluidicly coupled to the portion of the first internal passage via the one or more third flow ports; and wherein, when the sliding sleeve is in the second position, the annular region is fluidicly isolated from the portion of the first internal passage. In an exemplary embodiment, the sliding sleeve comprises one or more longitudinally-extending channels; and wherein the fluid control device further comprises one or more protrusions extending from the tubular support and into respective ones of the channels. In an exemplary embodiment, the apparatus comprises a support member coupled to the fluid control device and defining one or more radial passages; an expansion device coupled to the support member and comprising an external expansion surface; one or more rupture discs coupled to and positioned within corresponding radial passages of the support member; an expandable tubular member coupled to the expansion surface of the expansion device, the expandable tubular member comprising a first portion and a second portion, wherein the inside diameter of the first portion is less than the inside diameter of the second portion; and a shoe defining one or more internal passages coupled to the second portion of the expandable tubular member and to the fluid control device.

A method has been described that includes injecting fluidic materials into a sliding sleeve at least partially received within a tubular support, the tubular support defining an internal passage, a portion of which is at least partially defined by the sliding sleeve; conveying the fluidic materials out of the sliding sleeve and the tubular support; and conveying the fluidic materials into the portion of the internal passage of the tubular support at least partially defined by the sliding sleeve after conveying the fluidic materials out of the sliding sleeve and the tubular support. In an exemplary embodiment, the sliding sleeve comprises one or more first flow ports and the tubular support comprises one or more second flow ports; and wherein conveying the fluidic materials out of the sliding sleeve and the tubular support comprises aligning the one or more first flow ports of the sliding sleeve with respective ones of the one or more second flow ports of the tubular support; and conveying the fluidic materials through the one or more first flow ports and the one or more second flow ports aligned therewith, respectively. In an exemplary embodiment, the method further comprises blocking the flow of fluidic materials through the one or more first flow ports and the one or more second flow ports aligned therewith, respectively. In an exemplary embodiment, the method comprises blocking the flow of fluidic materials through the one or more first flow ports and the one or more second flow ports aligned therewith, respectively, comprises injecting a plug valve element into the sliding sleeve; and causing the plug valve element and the sliding sleeve to move axially in a direction, relative to the tubular support. In an exemplary embodiment, the method further comprises guiding the axial movement of the sliding sleeve, relative to the tubular support, during causing the plug valve element and the sliding sleeve to move axially in the direction, relative to the tubular support. In an exemplary embodiment, the method further comprises preventing any further axial movement of the sliding sleeve in the direction after causing the plug valve element and the sliding sleeve to move axially in the direction, relative to the tubular support. In an exemplary embodiment, the method further comprises locking the sliding sleeve to the tubular support; and unlocking the sliding sleeve from the tubular support. In an exemplary embodiment, locking the sliding sleeve to the tubular support comprises extending one or more pins from the tubular support and into the sliding sleeve; and wherein unlocking the sliding sleeve from the tubular support comprises shearing the one or more pins extending from the tubular support and into the sliding sleeve in response to causing the plug valve element and the sliding sleeve to move axially in the direction, relative to the tubular support. In an exemplary embodiment, the method further comprises fluidicly isolating the internal passage of the sliding sleeve from the portion of the internal passage of the tubular support at least partially defined by the sliding sleeve. In an exemplary embodiment, the method further comprises generally preventing relative rotation between the sliding sleeve and the tubular support. In an exemplary embodiment, an outer sleeve is coupled to the tubular support and an annular region is defined between the tubular support and the outer sleeve; wherein conveying the fluidic materials out of the sliding sleeve and the tubular support comprises conveying the fluidic materials out of the sliding sleeve and the tubular support and into the annular region defined between the tubular support and the outer sleeve; and wherein conveying the fluidic materials into the portion of the internal passage of the tubular support at least partially defined by the sliding sleeve after conveying the fluidic materials out of the sliding sleeve and the tubular support comprises fluidicly coupling the annular region defined between the tubular support and the outer sleeve to the portion of the internal passage of the tubular support at least partially defined by the sliding sleeve. In an exemplary embodiment, the method further comprises coupling an expandable tubular member to the tubular support; positioning the expandable tubular member within a preexisting structure; radially expanding and plastically deforming the expandable tubular member within the preexisting structure. In an exemplary embodiment, the method further comprises injecting fluidic materials into an annulus defined between the expandable tubular member and the preexisting structure. In an exemplary embodiment, the sliding sleeve comprises one or more first flow ports and the tubular support comprises one or more second flow ports; and wherein conveying the fluidic materials out of the sliding sleeve and the tubular support comprises aligning the one or more first flow ports of the sliding sleeve with respective ones of the one or more second flow ports of the tubular support; and conveying the fluidic materials through the one or more first flow ports and the one or more second flow ports aligned therewith, respectively; wherein the method further comprises blocking the flow of fluidic materials through the one or more first flow ports and the one or more second flow ports aligned therewith, respectively; and wherein radially expanding and plastically deforming the expandable tubular member within the preexisting structure comprises coupling one or more other tubular supports to the expandable tubular member and the tubular support within which the sliding sleeve is at least partially received; injecting fluidic material into the one or more other tubular supports after blocking the flow of fluidic materials through the one or more first flow ports and the one or more second flow ports aligned therewith, respectively; sensing the operating pressure of the fluidic material injected into the one or more other tubular supports; and if the sensed operating pressure of the fluidic material injected into the one or more other tubular supports exceeds a predetermined value, then radially expanding and plastically deforming the expandable tubular member within the preexisting structure.

An apparatus has been described that includes a tubular support defining a first internal passage and comprising one or more first flow ports; a sliding sleeve at least partially received within the first internal passage and sealingly engaging the tubular support, the sliding sleeve defining a second internal passage into which fluidic materials are adapted to be injected, the sliding sleeve comprising one or more second flow ports; one or more longitudinally-extending channels; a first position in which the first flow ports are aligned with respective ones of the second flow ports; and a second position in which the first flow ports are not aligned with the respective ones of the second flow ports; one or more protrusions extending from the tubular support and into respective ones of the channels of the sliding sleeve; a valve coupled to the tubular support, the valve comprising a movable valve element for controllably sealing an opening of the first internal passage of the tubular support; one or more pins extending into the sliding sleeve; an outer sleeve coupled to the tubular support so that an annular region is defined between the tubular support and the outer sleeve; a plurality of axially-spaced sealing elements coupled to the sliding sleeve and sealingly engaging the tubular support, wherein the second flow ports are axially positioned between two of the sealing elements; wherein, when the sliding sleeve is in the first position, the annular region is fluidicly coupled to the second internal passage of the sliding sleeve via the first flow ports and the second flow ports aligned therewith, respectively; wherein, when the sliding sleeve is in the second position, the annular region is fluidicly isolated from the second internal passage of the sliding sleeve; wherein, when the sliding sleeve is in the first position, the one or more pins extend from the tubular support and into the sliding sleeve to maintain the sliding sleeve in the first position; wherein, when the sliding sleeve is in the second position, the one or more pins are sheared to permit the sliding sleeve to move between the first and second positions; wherein the tubular support further comprises one or more third flow ports axially spaced from the one or more first flow ports; wherein, when the sliding sleeve is in the first position, a portion of the first internal passage of the tubular support is defined by the sliding sleeve; wherein, when the sliding sleeve is in the first position, the annular region is fluidicly coupled to the portion of the first internal passage via the one or more third flow ports; and wherein, when the sliding sleeve is in the second position, the annular region is fluidicly isolated from the portion of the first internal passage.

A method has been described that includes injecting fluidic materials into a sliding sleeve at least partially received within a tubular support, the tubular support defining an internal passage, a portion of which is at least partially defined by the sliding sleeve, the sliding sleeve comprising one or more first flow ports and the tubular support comprising one or more second flow ports; conveying the fluidic materials out of the sliding sleeve and the tubular support, comprising aligning the one or more first flow ports of the sliding sleeve with respective ones of the one or more second flow ports of the tubular support; and conveying the fluidic materials through the one or more first flow ports and the one or more second flow ports aligned therewith, respectively; conveying the fluidic materials into the portion of the internal passage of the tubular support at least partially defined by the sliding sleeve after conveying the fluidic materials out of the sliding sleeve and the tubular support; blocking the flow of fluidic materials through the one or more first flow ports and the one or more second flow ports aligned therewith, respectively, comprising injecting a plug valve element into the sliding sleeve; and causing the plug valve element and the sliding sleeve to move axially in a direction, relative to the tubular support; guiding the axial movement of the sliding sleeve, relative to the tubular support, during causing the plug valve element and the sliding sleeve to move axially in the direction, relative to the tubular support; preventing any further axial movement of the sliding sleeve in the direction after causing the plug valve element and the sliding sleeve to move axially in the direction, relative to the tubular support; locking the sliding sleeve to the tubular support, comprising extending one or more pins from the tubular support and into the sliding sleeve; unlocking the sliding sleeve from the tubular support, comprising shearing the one or more pins extending from the tubular support and into the sliding sleeve in response to causing the plug valve element and the sliding sleeve to move axially in the direction, relative to the tubular support; generally preventing relative rotation between the sliding sleeve and the tubular support; wherein an outer sleeve is coupled to the tubular support and an annular region is defined between the tubular support and the outer sleeve; wherein conveying the fluidic materials out of the sliding sleeve and the tubular support further comprises conveying the fluidic materials out of the sliding sleeve and the tubular support and into the annular region defined between the tubular support and the outer sleeve; and wherein conveying the fluidic materials into the portion of the internal passage of the tubular support at least partially defined by the sliding sleeve after conveying the fluidic materials out of the sliding sleeve and the tubular support comprises fluidicly coupling the annular region defined between the tubular support and the outer sleeve to the portion of the internal passage of the tubular support at least partially defined by the sliding sleeve.

A system has been described that includes means for injecting fluidic materials into a sliding sleeve at least partially received within a tubular support, the tubular support defining an internal passage, a portion of which is at least partially defined by the sliding sleeve; means for conveying the fluidic materials out of the sliding sleeve and the tubular support; and means for conveying the fluidic materials into the portion of the internal passage of the tubular support at least partially defined by the sliding sleeve after conveying the fluidic materials out of the sliding sleeve and the tubular support. In an exemplary embodiment, the sliding sleeve comprises one or more first flow ports and the tubular support comprises one or more second flow ports; and wherein means for conveying the fluidic materials out of the sliding sleeve and the tubular support comprises means for aligning the one or more first flow ports of the sliding sleeve with respective ones of the one or more second flow ports of the tubular support; and means for conveying the fluidic materials through the one or more first flow ports and the one or more second flow ports aligned therewith, respectively. In an exemplary embodiment, the system further comprises means for blocking the flow of fluidic materials through the one or more first flow ports and the one or more second flow ports aligned therewith, respectively. In an exemplary embodiment, means for blocking the flow of fluidic materials through the one or more first flow ports and the one or more second flow ports aligned therewith, respectively, comprises means for injecting a plug valve element into the sliding sleeve; and means for causing the plug valve element and the sliding sleeve to move axially in a direction, relative to the tubular support. In an exemplary embodiment, the system further comprises means for guiding the axial movement of the sliding sleeve, relative to the tubular support, during causing the plug valve element and the sliding sleeve to move axially in the direction, relative to the tubular support. In an exemplary embodiment, the system further comprises means for preventing any further axial movement of the sliding sleeve in the direction after causing the plug valve element and the sliding sleeve to move axially in the direction, relative to the tubular support. In an exemplary embodiment, the system further comprises means for locking the sliding sleeve to the tubular support; and means for unlocking the sliding sleeve from the tubular support. In an exemplary embodiment, means for locking the sliding sleeve to the tubular support comprises means for extending one or more pins from the tubular support and into the sliding sleeve; and wherein means for unlocking the sliding sleeve from the tubular support comprises means for shearing the one or more pins extending from the tubular support and into the sliding sleeve in response to causing the plug valve element and the sliding sleeve to move axially in the direction, relative to the tubular support. In an exemplary embodiment, the system further comprises means for fluidicly isolating the internal passage of the sliding sleeve from the portion of the internal passage of the tubular support at least partially defined by the sliding sleeve. In an exemplary embodiment, the system further comprises means for generally preventing relative rotation between the sliding sleeve and the tubular support. In an exemplary embodiment, an outer sleeve is coupled to the tubular support and an annular region is defined between the tubular support and the outer sleeve; wherein means for conveying the fluidic materials out of the sliding sleeve and the tubular support comprises means for conveying the fluidic materials out of the sliding sleeve and the tubular support and into the annular region defined between the tubular support and the outer sleeve; and wherein means for conveying the fluidic materials into the portion of the internal passage of the tubular support at least partially defined by the sliding sleeve after conveying the fluidic materials out of the sliding sleeve and the tubular support comprises means for fluidicly coupling the annular region defined between the tubular support and the outer sleeve to the portion of the internal passage of the tubular support at least partially defined by the sliding sleeve. In an exemplary embodiment, the system further comprises means for coupling an expandable tubular member to the tubular support; means for positioning the expandable tubular member within a preexisting structure; means for radially expanding and plastically deforming the expandable tubular member within the preexisting structure. In an exemplary embodiment, the system further comprises means for injecting fluidic materials into an annulus defined between the expandable tubular member and the preexisting structure. In an exemplary embodiment, the sliding sleeve comprises one or more first flow ports and the tubular support comprises one or more second flow ports; and wherein means for conveying the fluidic materials out of the sliding sleeve and the tubular support comprises means for aligning the one or more first flow ports of the sliding sleeve with respective ones of the one or more second flow ports of the tubular support; and means for conveying the fluidic materials through the one or more first flow ports and the one or more second flow ports aligned therewith, respectively; wherein the system further comprises means for blocking the flow of fluidic materials through the one or more first flow ports and the one or more second flow ports aligned therewith, respectively; and wherein means for radially expanding and plastically deforming the expandable tubular member within the preexisting structure comprises means for coupling one or more other tubular supports to the expandable tubular member and the tubular support within which the sliding sleeve is at least partially received; means for injecting fluidic material into the one or more other tubular supports after blocking the flow of fluidic materials through the one or more first flow ports and the one or more second flow ports aligned therewith, respectively; means for sensing the operating pressure of the fluidic material injected into the one or more other tubular supports; and means for if the sensed operating pressure of the fluidic material injected into the one or more other tubular supports exceeds a predetermined value, then radially expanding and plastically deforming the expandable tubular member within the preexisting structure.

An apparatus has been described that includes a flow control device comprising a tubular support defining a first internal passage and comprising one or more first flow ports; a sliding sleeve at least partially received within the first internal passage and sealingly engaging the tubular support, the sliding sleeve defining a second internal passage into which fluidic materials are adapted to be injected, the sliding sleeve comprising one or more second flow ports; a first position in which the first flow ports are aligned with respective ones of the second flow ports to thereby permit the fluidic materials to flow out of the second internal passage; and a second position in which the first flow ports are not aligned with the respective ones of the second flow ports to thereby prevent the fluidic materials from flowing out of the second internal passage; a plurality of axially-spaced sealing elements coupled to the sliding sleeve and sealingly engaging the tubular support, wherein the second flow ports are axially positioned between two of the sealing elements; one or more pins extending into the sliding sleeve; and a valve coupled to the tubular support, the valve comprising a movable valve element for controllably sealing an opening of the first internal passage of the tubular support; a plug valve element adapted to be seated in the second internal passage of the sliding sleeve of the flow control device; a support member coupled to the fluid control device and defining one or more radial passages; an expansion device coupled to the support member and comprising an external expansion surface; one or more rupture discs coupled to and positioned within corresponding radial passages of the support member; an expandable tubular member coupled to the expansion surface of the expansion device, the expandable tubular member comprising a first portion and a second portion, wherein the inside diameter of the first portion is less than the inside diameter of the second portion; and a shoe defining one or more internal passages coupled to the second portion of the expandable tubular member and to the fluid control device; wherein the tubular support of the fluid control device further comprises one or more third flow ports axially spaced from the one or more first flow ports; wherein, when the sliding sleeve is in the first position, the one or more pins extend from the tubular support and into the sliding sleeve to maintain the sliding sleeve in the first position; and wherein, when the sliding sleeve is in the second position, the one or more pins are sheared to permit the sliding sleeve to move between the first and second positions.

A system has been described that includes means for injecting fluidic materials into a sliding sleeve at least partially received within a tubular support, the tubular support defining an internal passage, a portion of which is at least partially defined by the sliding sleeve, the sliding sleeve comprising one or more first flow ports and the tubular support comprising one or more second flow ports; means for conveying the fluidic materials out of the sliding sleeve and the tubular support, comprising means for aligning the one or more first flow ports of the sliding sleeve with respective ones of the one or more second flow ports of the tubular support; and means for conveying the fluidic materials through the one or more first flow ports and the one or more second flow ports aligned therewith, respectively; means for conveying the fluidic materials into the portion of the internal passage of the tubular support at least partially defined by the sliding sleeve after conveying the fluidic materials out of the sliding sleeve and the tubular support; means for blocking the flow of fluidic materials through the one or more first flow ports and the one or more second flow ports aligned therewith, respectively, comprising means for injecting a plug valve element into the sliding sleeve; and means for causing the plug valve element and the sliding sleeve to move axially in a direction, relative to the tubular support; means for guiding the axial movement of the sliding sleeve, relative to the tubular support, during causing the plug valve element and the sliding sleeve to move axially in the direction, relative to the tubular support; means for preventing any further axial movement of the sliding sleeve in the direction after causing the plug valve element and the sliding sleeve to move axially in the direction, relative to the tubular support; means for locking the sliding sleeve to the tubular support, comprising means for extending one or more pins from the tubular support and into the sliding sleeve; means for unlocking the sliding sleeve from the tubular support, comprising means for shearing the one or more pins extending from the tubular support and into the sliding sleeve in response to causing the plug valve element and the sliding sleeve to move axially in the direction, relative to the tubular support; means for generally preventing relative rotation between the sliding sleeve and the tubular support; wherein an outer sleeve is coupled to the tubular support and an annular region is defined between the tubular support and the outer sleeve; wherein means for conveying the fluidic materials out of the sliding sleeve and the tubular support further comprises means for conveying the fluidic materials out of the sliding sleeve and the tubular support and into the annular region defined between the tubular support and the outer sleeve; and wherein means for conveying the fluidic materials into the portion of the internal passage of the tubular support at least partially defined by the sliding sleeve after conveying the fluidic materials out of the sliding sleeve and the tubular support comprises means for fluidicly coupling the annular region defined between the tubular support and the outer sleeve to the portion of the internal passage of the tubular support at least partially defined by the sliding sleeve.

It is understood that variations may be made in the foregoing without departing from the scope of the disclosure. In several exemplary embodiments, the teachings of the present illustrative embodiments may be used to provide, form and/or repair a wellbore casing, a pipeline, a structural support and/or any combination thereof. In several exemplary embodiments, the wellbore 36 may be an open wellbore, a cased wellbore and/or any combination thereof.

Any spatial references such as, for example, “upper,” “lower,” “above,” “below,” “between,” “vertical,” “horizontal,” “angular,” “upward,” “downward,” “side-to-side,” “left-to-right,” “right-to-left,” “top-to-bottom,” “bottom-to-top,” “top,” “bottom,” etc., are for the purpose of illustration only and do not limit the specific orientation or location of the structure described above.

In several exemplary embodiments, one or more of the operational steps in each embodiment may be omitted. Moreover, in some instances, some features of the present disclosure may be employed without a corresponding use of the other features. Moreover, one or more of the above-described embodiments and/or variations may be combined in whole or in part with any one or more of the other above-described embodiments and/or variations.

Although several exemplary embodiments have been described in detail above, the embodiments described are exemplary only and are not limiting, and those skilled in the art will readily appreciate that many other modifications, changes and/or substitutions are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of the present disclosure. Accordingly, all such modifications, changes and/or substitutions are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.

Claims

1. A system comprising:

a tubular support having a first internal passage and a flow passage;
a sliding sleeve disposed in the first internal passage, the sliding sleeve having a second internal passage and being moveable by fluid pressure between a first position, wherein the second internal passage is in fluid communication with a first annulus surrounding the tubular support, and a second position, wherein the second internal passage is fluidicly isolated from the first annulus;
a rupture disc seated in the flow passage, the rupture disc fluidicly isolating the first internal passage from a second annulus surrounding the tubular support and adapted to rupture, whereby the first internal passage and the second annulus are fluidicly coupled; and
an expansion cone disposed in the second annulus and moveable under pressure from fluid in the second annulus.

2. The system of claim 1, further comprising:

one or more shear pins extending into the sliding sleeve, the shear pins configured to maintain the sliding sleeve in the first position and shearable to enable movement of the sliding sleeve from the first position toward the second position.

3. The system of claim 1, further comprising:

a plug valve element adapted to be seated in the second internal passage of the sliding sleeve.

4. The system of claim 1, wherein the tubular support further comprises one or more first flow ports and the sliding sleeve comprises one or more second flow orts and wherein the first and second flow ports are aligned when the sliding sleeve is in the first position, whereby the second internal passage and the first annulus are fluidicly coupled, and are misaligned when the sliding sleeve is in the second position.

5. The system of claim 4, wherein the sliding sleeve divides the first internal passage into an upper portion defined by the second internal passage and a lower portion below the sliding sleeve and the tubular support further comprises one or more third flow ports axially spaced from the first flow ports, the third flow ports fluidicly coupling the first annulus with the lower portion of the first internal passage.

6. The system of claim 5, further comprising a valve disposed in an opening of the tubular support and actuatable by fluid pressure in the lower portion of the tubular support between an open configuration, wherein fluid passes through the opening, and a closed configuration, wherein fluid is prevented from passing through the opening.

7. The system of claim 1, wherein the first annulus is fluidicly isolated from the second annulus.

8. The system of claim 7, wherein the first annulus is defined by the tubular support and an outer sleeve coupled thereto.

9. A method comprising:

disposing a tubular support having a first internal passage within an expandable tubular;
positioning an expansion cone in an annulus between the expandable tubular and the tubular support;
disposing a sliding sleeve in the first internal passage, the sliding sleeve dividing the first internal passage into an upper portion above the sliding sleeve and a lower portion below the sliding sleeve and having a second internal passage fluidicly coupled to the upper portion;
fluidicly isolating the annulus from the upper portion;
fluidicly coupling the lower portion and the second internal passage;
injecting fluidic materials from the upper portion through the second internal passage into the lower portion;
opening a valve disposed in an opening of the tubular support proximate the lower portion, whereby the fluid material passes through the opening from the tubular support;
moving the sliding sleeve by fluid pressure acting thereon, thereby fluidicly isolating the lower portion from the second internal passage and fluidicly coupling the upper portion with the annulus;
diverting fluidic materials from the upper into the annulus; and
moving the expansion cone relative to the tubular support by fluid pressure applied thereto, thereby radially expanding the expandable tubular.

10. The method of claim 9, wherein said fluidicly coupling of the lower portion and the second internal passage comprises:

aligning one or more first flow ports in the tubular support and one or more second flow ports in the sliding sleeve; and
extending one or more shear pins from the tubular support through the sliding sleeve, whereby the position of the sliding sleeve relative to the tubular support is maintained and the first and second flow ports are aligned.

11. The method of claim 10, wherein said fluidicly isolating the lower portion from the second internal passage comprises:

injecting fluidic materials from the upper portion of the first internal passage to the second internal passage;
delivering a plug element into the second internal passage with the injected fluidic materials;
increasing a pressure of the injected fluidic materials acting on the plug element and the sliding sleeve;
shearing the shear pins in response to the increasing fluid pressure;
moving the sliding sleeve relative to the tubular support; and
misaligning the first and second flow ports.

12. The method of claim 11, further comprising:

guiding the sliding sleeve as the sliding sleeve moves relative to the tubular support.

13. The method of claim 11, further comprising:

preventing rotation of the sliding sleeve as the sliding sleeve moves relative to the tubular support.

14. The method of claim 9, wherein said fluidicly isolating the annulus from the upper portion comprises:

disposing a rupture disc in a flow passage extending through the tubular support between the upper portion and the annulus.

15. The method of claim 14, wherein said fluidicly coupling the annulus and the upper portion comprises:

increasing fluid pressure in the upper portion; and
rupturing the rupture disc, whereby fluid communication between the annulus and the upper portion is established.

16. A system comprising:

a tubular support having a first internal passage;
a sliding sleeve disposed in the first internal passage and dividing the first internal passage into an upper portion above the sliding sleeve and a lower portion below the sliding sleeve, the sliding sleeve having a second internal passage fluidicly coupled to the upper portion and being moveable under fluid pressure between a first position, wherein the second internal passage is fluidicly coupled to the lower portion, and a second position, wherein the second internal passage is fluidicly isolated from the lower portion;
one or more shear pins extending from the tubular support into the sliding sleeve, the shear pins configured to maintain the sliding sleeve in the first position and being shearable to enable movement of the sliding sleeve from the first position toward the second position; and
an expansion cone disposed in an annulus external to the tubular support, the expansion cone moveable by fluid pressure acting thereon relative to the tubular support when the annulus is fluidicly coupled to the upper portion of the first internal passage.

17. The system of claim 16, wherein the sliding sleeve is adapted to receive a plug element therein.

18. The system of claim 16, wherein the tubular support further comprises one or more first flow ports and the sliding sleeve comprises one or more second flow ports; and wherein the first and second flow ports are aligned when the sliding sleeve is in the first position, whereby the second internal passage and the lower portion are fluidicly coupled, and are misaligned when the sliding sleeve is in the second position.

19. The system of claim 16, further comprising a valve disposed in an opening of the tubular support and actuatable by fluid pressure in the lower portion of the tubular support between an open configuration, wherein fluid passes through the opening, and a closed configuration, wherein fluid is prevented from passing through the opening.

20. The system of claim 16, further comprising one or more protrusions extending radially from the tubular support into one or more channels formed in the outer surface of the sliding sleeve, the protrusions limiting movement of the sliding sleeve relative to the tubular support.

21. The system of claim 16, wherein the tubular support comprises a flow passage extending between the annulus and the upper portion of the first internal passage and a rupture disc seated in the flow passage, the rupture disc fluidicly isolating the first internal passage from the annulus and adapted to rupture, whereby the first internal passage and the annulus are fluidicly coupled.

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Patent History
Patent number: 7886831
Type: Grant
Filed: Aug 6, 2007
Date of Patent: Feb 15, 2011
Patent Publication Number: 20080083541
Assignee: Enventure Global Technology, L.L.C. (Houston, TX)
Inventors: Charles Anthony Butterfield, Jr. (Cypress, TX), David Paul Brisco (Duncan, OK)
Primary Examiner: David J Bagnell
Assistant Examiner: David Andrews
Attorney: Conley Rose, P.C.
Application Number: 11/834,401
Classifications
Current U.S. Class: Conduit (166/380); Cementing Device (166/177.4); Expansible Casing (166/207)
International Classification: E21B 43/00 (20060101);